Canted coil spring power terminal and sequence connection system

ABSTRACT

The present invention provides an electrical power system comprising a plurality of battery modules in series connection between adjacent battery modules, wherein each of the battery modules comprises a positive male terminal, a negative male terminal, and a socket corresponding to each of the positive male terminals and the negative male terminals. The connectors connecting the adjacent battery modules include a sequence tab that provides an irreversible engagement sequence of the connectors into the sockets of the adjacent battery modules. The irreversible engagement sequence positions an insulating portion of the connectors housing on each positive male terminal of the battery modules that are in series connection in order to isolate the positive male terminals from human contact. The present invention also provides a female terminal including a canted coil spring positioned within a stamped groove that may be housed within the above-described connectors.

FIELD OF THE INVENTION

The present invention relates to high current electrical connections, inwhich electrical communication between male and female terminals isprovided by a canted coil spring interface. The present inventionfurther relates to high voltage battery modules comprising a series ofconnectors having a structure that dictates an assembly sequence thatsubstantially eliminates the incidence of high voltage electrocution.

BACKGROUND OF THE INVENTION

Male and female terminals in high current electrical connection systemsare currently locked by terminals incorporating exterior plasticinterlocking structures. The incorporation of the additional plasticinterlocking structures to the exterior of the terminalsdisadvantageously increases the overall dimensions of the connectors.The increased dimensions of connectors having additional interlockingstructures presents a number of design challenges for integration of theconnectors into higher current electronics requiring increasedelectrical connector density.

One improvement to electrical terminals having interior interlockingstructures are terminals including a canted coil spring, wherein thecanted coil spring is positioned into a groove machined within the bodyof the female terminals. Prior canted coil spring terminals require thatthe groove be machined within each side of the female terminal body andthat the coil spring be inserted into the machined groove in the femaleterminal body. The cost of the machining in producing each of the priorcanted coil spring terminals is high.

Hybrid Electrical Vehicle (HEV) battery packs consist of number ofbattery modules, wherein each battery module has a plurality of batterycells. Typically, the battery modules are in electrical communicationthrough module to module series connections and the battery cells are inelectrical communication through cell to cell series connections.Currently, existing cell to cell connections use a welding process andmodule to module connections use nut-bolt fastening methods. Theseprocesses cause a variety of manufacturing obstacles and safetyconcerns.

Welding cell to cell connections presents a number of obstacles inmanufacturing and servicing. Welding introduces elevated temperatures tothe battery cell, which can damage the battery cell. In certain batterytypes, such as Lithium Ion batteries, the elevated temperaturesassociated with welding may be the source of an explosion. Further, whenutilized in hybrid electrical vehicle applications, welded cell to cellbattery packs are not economical to replace, since welded cells are notserviceable during manufacturing or during consumer maintanence.

Module to module connections require nut and bolt arrangements that alsoprovide a number of difficulties, since this manufacturing method isprone to over-torquing or under-torquing of the nut and bolt fasteners.Additionally, cross threading of the bolts is also common, which maydestroy the positive or negative battery post when over-torqued. Theconcise assembly required for high voltage battery module manufacturingand the need for closely monitored torque control render bolt and nutarrangements uneconomical for high voltage battery module manufacturing.

Further, methods for manufacturing high voltage battery modules presenta number of dangers to those handling the high voltage battery modulesduring and after the manufacturing process. Although, each moduleusually has less than a 50 volt capacity, battery modules are currentlybeing connected in series in order to meet the increasing demands ofhigh-voltage applications, in which voltage levels on the order of about100 volts to greater than 600 volts are presenting a number ofchallenges for ensuring safety during the manufacture of these highvoltage connections using typical manufacturing methods.

In light of the above, what is needed is an electrical connector systemfor high current and high voltage applications that can be manufacturedin an economical and safe fashion. Further, a need exists for amaintanence serviceable battery pack in which electrical connectors maybe reliably and safely manufactured.

SUMMARY OF THE INVENTION

These needs, and others, are met by the present invention which providesan electrical terminal system suitable for high current applications,wherein the electrical terminal system includes a female terminal bodyhaving a stamped groove for accepting a canted coil spring and anopening having a geometry configured for accepting the inserting portionof a male terminal body. Electrical communication between the male andfemale terminal bodies is provided by an interface between the cantedcoil spring and the inserting portion of the male terminal body.Broadly, the inventive electrical terminal system comprises:

a male terminal body comprising an inserting portion;

a female terminal body having at least one open end for receiving saidinserting portion of said male terminal body, said female terminal bodycomprising a stamped groove positioned corresponding to said insertedportion of said male terminal body when said female terminal body andsaid male terminal body are engaged; and

a canted coil spring for providing an electrical interface between saidmale terminal body and said female terminal body, said canted coilspring positioned in said stamped groove.

The canted coil spring incorporated into the female terminal body iscurvilinear in shape, wherein the opposing ends of the canted coilspring are mechanically connected or welded. The female terminal body isformed from a stamped sheet in which the stamped groove of the femaleterminal body is positioned in a portion of the stamped sheet metal thatis folded during forming of the female terminal body into a geometry foraccepting the inserting portion of the male terminal body.

The inserting portion of the male terminal body comprises a rounded pinhaving at least one groove for reversibly interlocking with the cantedcoil spring within the female terminal body. During engagement of themale and female terminal bodies, the inserting portion of the maleterminal body is in communicative contact with the canted coil springproviding an electrical interface between the male and female terminalbodies.

Another aspect of the present invention is a method for manufacturingthe above-described electrical terminal that incorporates a canted coilspring within a stamped groove of a female terminal body. Broadly, theinventive method comprises the steps of:

providing a stamped metal panel comprising a stamped groove about anopening for inserting a male terminal;

inserting a canted coil spring into said stamped groove; and

folding a portion of said metal panel to contain said canted coil springwithin said groove.

Another aspect of the present invention is an electrical power systemthat may incorporate the above described stamped female terminal body.Broadly, the inventive electrical power system comprises:

a plurality of battery modules in series connection between adjacentbattery modules, wherein each battery module of said plurality ofbattery modules comprises a positive male terminal, a negative maleterminal, and a socket corresponding to each of said positive maleterminal and said negative male terminal; and

a plurality of connectors, in which each terminal of said plurality ofsaid connectors is in engagement with said socket of said positive maleterminal and said negative male terminal of said adjacent batterymodules, said each connector comprises an insulating structure housing afemale terminal, said female terminal providing said series connectionbetween said positive male terminal and said negative male terminal ofsaid adjacent battery modules, said insulating structure comprising asequence tab configured to provide an irreversible engagement sequenceof said plurality of connectors within said sockets of said adjacentbattery modules, wherein said irreversible engagement sequence positionssaid insulating structure atop said positive male terminal of saidplurality of battery modules in series connection.

In the above described electrical power system, the irreversibleengagement sequence ensures that the positive male terminal betweenadjacent battery modules in series engagement is not exposed. Theincorporation of the sequence tab in combination with an insulative cappositioned atop the first positive male terminal of the first batterymodule in the assembling sequence substantially eliminates thepossibility of high voltage electrocution during assembling andservicing of battery modules that are in series connection.

The insulative cap is positioned on the upper most portion of theinserting portion of the first positive male terminal leaving an exposedportion first positive male terminal extending below the insulative cap,in which the exposed portion is surrounded by an insulating shroud. Thecombination of the insulating cap and the insulating shroud in thecorrect dimensions provides increased safety by substantiallyeliminating incidental contact to the exposed portion of the positivemale terminals. The term “incidental contact” denotes that thedimensions of the insulating cap and the insulating shroud ensure that aperson handling the battery modules can not contact the exposed portionof the positive male terminal.

In another embodiment of the present invention, as opposed to only thefirst positive male terminal of the first battery module in theassembling sequence having an insulative cap and shroud, each of thepositive male terminals on each battery module comprises an insulativecap and insulating shroud.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the followingdescription of the preferred embodiments when read in conjunction withthe accompanying drawings in which:

FIG. 1 (isometric view) illustrates a canted coil spring.

FIG. 2 a (isometric view) illustrates one embodiment of a femaleterminal body having a canted coil spring positioned within a stampedgroove.

FIG. 2 b (cross-section view) illustrates one embodiment of a femaleterminal body having a canted coil spring positioned within a stampedgroove depicted in FIG. 2 a.

FIG. 2 c (isometric view) depicts a series of battery cells, in whichelectrical communication by series connection is provided by the femaleterminal body depicted in FIGS. 2 a and 2 b.

FIG. 2 d (cross-section view) depicts the male terminal of two batterycells having a geometry for engaging a the female terminal body depictedin FIG. 2 c.

FIG. 3 a (isometric view) illustrates another embodiment of a femaleterminal body having two openings for accepting the inserting portion ofa male terminal, each opening of the female terminal body having acanted coil spring positioned within a stamped groove.

FIG. 3 b (cross-section view) illustrates the cross-section of theterminal body depicted in FIG. 3 a.

FIG. 3 c (isometric view) depicts another embodiment of a femaleterminal body having two openings for accepting the inserting portion ofa male terminal body, in which each opening of the female terminal bodyhas a contact spring press fitted within a stamped sleeve.

FIG. 4 (isometric view) illustrates a single female terminal similar inorientation to the female terminal bodies depicted in FIG. 3 and a maleterminal body having a geometry corresponding to the opening of thefemale terminal body.

FIG. 5 (side view) depicts the female terminal body and the maleterminal body of FIG. 4 each positioned within an unsealed housing.

FIG. 6 (side view) depicts a female terminal body engaged with a maleterminal body, wherein the female and male terminal bodies arepositioned within a housing adapted to provide a sealing engagement.

FIGS. 7 a-7 c (isometric view) depict connectors having a geometrycorresponding to the female terminal body depicted in FIGS. 3 a-3 c.

FIG. 8 (isometric view) depicts an alternative female terminal bodyhaving a polyhedron shaped opening configuration.

FIG. 9 (isometric view) depicts a connector having a geometrycorresponding to the female terminal body depicted in FIG. 8.

FIG. 10 (isometric view) depicts a plurality of battery modules inseries connection through a number of connectors, as depicted in FIG. 9,wherein each connector houses a female terminal body, as depicted inFIG. 8.

FIG. 11 a (isometric view) and FIG. 11 b depict an insulative cap thatmay be positioned atop an upper portion of the inserting portion of themale terminal body.

FIG. 12 a (isometric view) depicts a plurality of battery modules inseries connection in which each positive male terminal comprises aninsulative cap, similar to that depicted in FIGS. 11 a and 11 b, atopits' uppermost surface.

FIG. 12 b (isometric view) depicts connectors engaged within the socketsof a plurality of battery modules in series connection, wherein each ofthe sockets houses a positive male terminal capped by an insulative cap,as depicted in FIG. 12 a.

FIG. 13 (top view) depicts a positive male connector having theinsulative cap depicted in FIG. 12, in which the dimensions of the capand the insulating shroud surrounding the positive male connectorprotect the positive male connector from incidental contact.

FIG. 14 (isometric view) depicts a plurality of battery modules inseries connection through a number of connectors, as depicted in FIGS. 7a-7 c, wherein only the first positive male terminal has an insulatingcap and the connectors are installed in an assembling sequence that isdictated by a sequence tab which ensures that each positive maleterminal of the battery modules that are in series connection areprotected by the insulative structure of the connector.

FIG. 14 a (isometric view) illustrates a magnified end portion of thebattery modules depicted in FIG. 14, indicated by reference line 14 a.

FIG. 14 b (isometric view) illustrates a magnified view of the interfacebetween adjacent connectors connecting the battery modules depicted inFIG. 14, indicated by reference line 14 b.

FIGS. 15 a-15 c (isometric view) depicts the locking engagement betweenthe connector and the socket in which the connector is inserted.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention provides an electrical terminal system suitablefor high current applications, wherein electrical communication betweenthe inserting portion of a male terminal body and a female terminal bodyis provided by a canted coil spring positioned within a groove stampedinto the female terminal body. The present invention also provides ameans for manufacturing an electrical terminal system, in which a cantedcoil spring is positioned within a groove that is stamped into thefemale connector body. The present invention further provides anelectrical connection system for cell to cell battery connections havingincreased reliability, safety and serviceability. The present inventionalso provides an electrical connection system for modular batterieshaving increased reliability, safety and serviceability. The presentinvention is now discussed in more detail referring to the drawings thataccompany the present application. In the accompanying drawings, likeand/or corresponding elements are referred to by like reference numbers.

FIG. 1 represents a canted coil spring 5 having a curvilinear shape,preferably being substantially circular. The curvilinear shape isprovided by connecting the opposing ends of the coil spring 5. Theopposing ends of the coil spring 5 may be welded or mechanicallyconnected. Although the canted coil spring 5 typically comprises metalalloy any conductive material may be selected that is known within theart.

The present invention provides a female terminal body formed of stampedsheet metal, in which a groove is stamped within the female terminalbody for accepting the canted coil spring 5 depicted in FIG. 1. Thestamped sheet metal comprises a material selected from the groupconsisting of copper, aluminum, steel, and combinations and alloysthereof. In a preferred embodiment, the stamped sheet metal comprisescopper alloy.

As shown in FIGS. 2 a and 2 b, in one embodiment of the female terminalbody 10, the groove 11 for receiving the canted coil spring 5 may bepositioned so that the dimension defining the diameter D₁ of the cantedcoil spring 5 is in a plane parallel to a dimension defining length L₁of the female terminal body 10. In this embodiment the opening isdisposed along a plane parallel to the length L₁ of the female terminalbody 10. This embodiment of the present invention advantageouslyprovides a female terminal body 10 having a substantially minimizedprofile.

In this embodiment of the present invention, the sheet metal is stampedto provide a preselected number of openings 12 configured for selectiveengagement to the inserting portion of the male terminal body 71, asdepicted in FIGS. 2 c and 2 d. The groove 11 for containing the cantedcoil spring 5 is positioned about each opening 12. The positioning ofthe groove 11 is selected to ensure that the canted coil spring 5provides electrical communication between the male terminal body 71 andthe female terminal body 10.

Referring back to FIGS. 2 a and 2 b, the stamped sheet metal is furtherconfigured to provide a folding over portion 15, wherein the foldingover portion 15 is folded over the portion of the stamped sheet metal inwhich the groove 11 is positioned to ensure that the canted coil spring5 is contained therein. The canted coil spring 5 may be positionedwithin the groove 11 while the folding over portion 15 is bent intoposition. Although FIGS. 2 a and 2 b depict a female terminal body 10having two openings 12, any number of openings 12 may be configured intothe female terminal body 10 including only a single opening and aretherefore within the scope of the present invention.

Referring to FIGS. 2 c and 2 d, the present invention also provides afemale terminal body 10 having an interior canted coil spring 5 andgroove 11 for engagement to a male post (terminal body) 71 positioned ona battery cell 72, in which each opening 12 is positioned to provide anelectronic pathway to the battery cell 72. The canted coil spring spring5 is interlocked within a grooved structure 83 on the male post 71, asshown in FIG. 2 d. The engagement of the canted coil spring 5 within thegrooved structure 83 of the male post 71 provides self interlockingfemale and male terminals. A flexible joint 73 between the openings 12,prefereably in the form of a U-shape loop, can be stretched orcompressed such that the distance L1 is adjusted accordingly. Theadjustability of the distance L1 between the openings 12 of the femaleterminal 10 provides for greater tolerances in the distance variancebetween two the male posts 71 of the battery cells 72.

Referring now to FIGS. 3 a-3 c, in another embodiment of the presentinvention, the female terminal body 10 is formed from a stamped metalsheet in which each opening 12 of the female terminal body 10 comprisesa rounded and cylindrical shape, as opposed to the flatter lower profilefemale terminal body 10 depicted in FIGS. 2 a-2 d. In this embodiment,the opening 12 in which the canted coil spring 5 is positioned isdisposed along a plane perpendicular to the dimension defining length L1of the female terminal body 10. Although the female terminal body 10 maycomprise any number of openings 12 for engagement with the male terminalbody (not shown), including a single opening, in the embodiments of thepresent invention including multiple openings each opening 12 may beseparated by an adjustable distance L1. Similar to the embodimentsdepicted in FIGS. 2 a-2 d, a U-shaped loop 73 may be incorporated intothe embodiment depicted in FIGS. 3 a-3 c and can be stretched orcompressed such that the distance L1 between the openings 12 may beadjusted, wherein the adjustable distance L1 provides greater tolerancein the distance variation between any two modules 40 a, 40 b that are inseries connection, as depicted in FIG. 8.

Referring to FIG. 3 c, in one embodiment of the present invention, thefemale terminal body 74 is formed from a stamped metal sheet in whicheach opening 12 of the female terminal body 74 comprises a rounded andcylindrical shape and a contact spring which is press fitted within thecylindrical sleeve. Although, the female terminal body 10 in FIGS. 3 a-3c preferably contains a canted coil spring positioned within a stampedgroove 11, alternatively a hourglass contact spring 79 may be pressedinto female terminal body 74 shown in FIG. 3 c.

Referring now to FIG. 4, depicting a male terminal body 20 and femaleterminal body 10, the male terminal body 20 comprises an insertingportion 25 having a geometry for engagement into the opening 12 of thefemale terminal body 10. In one embodiment of the present invention, theinserting portion 25 of the male terminal body 20 comprises a roundedpin comprising at least one groove 26. In this embodiment, at least oneof the grooves 26 in the male inserting portion 25 is adapted toreversibly interlock with the canted coil spring 5 contained within thestamped groove 12 of the female terminal body 10 when the male andfemale terminal bodies 20, 10 are engaged.

Still referring to FIG. 4, the male terminal body 20 may further includea male crimp end 27 for communicative engagement to at least one wire(not shown) opposite the inserting portion 25 of the male terminal body20. Additionally, the female terminal body 10 may include a female crimpend 13 opposite the open end 12 of the female terminal body 10 forcommunicative engagement to at least one other wire (not shown) than thewires connected to the male crimp end 27.

Referring to FIG. 5, each of the male and female terminal bodies 10, 20may be encased in a housing, wherein the housing may be adapted toprovide a sealed engagement between the male and female terminal bodies20,10 or an unsealed engagement between the male and female terminalbodies 20, 10. A sealed engagement may be provided by a female polymericstructure 14 shown in FIGS. 5 and 6 housing the female electricalterminal 10 and a male polymeric structure 28 housing the maleelectrical terminal 20, wherein engaging portions of the femalepolymeric structure 14 and the male polymeric structure 28 may providean interfacial seal when the male terminal body 20 and the femaleterminal body 10 are engaged. In another embodiment of the presentinvention, the interfacial seal between the female polymeric structure14 and the male polymeric structure 28 is provided by a sealing gasket16 at an interface defined by the joining portions of the male andfemale polymeric structures 28, 14, as shown in FIG. 6. The sealinggasket 16 may comprise any sealing material including a polymericmaterial.

Additionally, further sealing members 17 may be provided at the wireconnecting portions of the male and female polymeric structures 28, 14,wherein the wire connecting portions are opposite the inserting portion25 of the male terminal body 20 and the open end 12 of the femaleterminal body 10. The sealing members 17 may be formed from any materialthat may be adapted to provide a hermiadic seal.

Referring to FIGS. 7 a, 7 b, 7 c, the present invention also provides aconnector 30 having an interior geometry for accepting a stamped femaleterminal body 10, as depicted in FIG. 3 a-3 c, and an exterior geometryfor engagement to a socket 35 positioned on the housing of a modularbattery 40, in which each socket 35 is positioned to provide anelectronic pathway to the modular battery 40. The connector 30 typicallycomprises an insulative material housing (structure) such as a plasticmaterial. In a preferred embodiment, a plurality of sockets 35 arepositioned in an inline arrangement atop the modular battery 40, whereinthe engagement of multiple connectors 30 into the inline arrangement ofsockets 35 provides for a series connection between adjacent batterymodules, as depicted in FIGS. 12 b and 14.

Although the connectors 30 depicted in FIGS. 7 a-7 c have a geometry foraccepting the stamped female terminal body 10 depicted in FIGS. 3 a-3 c,it is noted that other geometries for the connectors 30 have beencontemplated and are within the scope of the present invention. Forexample, instead of the curvilinear shaped openings, the female terminalbody 10 a may have the at least two polyhedron shape openings 12 a, asdepicted in FIG. 8, and the connector 30 a may have a configuration toaccept the female terminal body 10 a comprising polyhedron shapedopenings 12 a, as depicted in FIG. 9. As shown in FIG. 10, the batterymodule 40 a may comprise a series of sockets 35 a for interlockinglyengaging the terminal housing 30 a depicted in FIG. 9.

Regardless of the connector geometry employed, each connector 30, 30 ahouses a female terminal body 10 in which the upper portion of theconnector 30, 30 a serves as a insulative cap to isolate the femaleterminal body 10 contained within the connector from contact by thoseassembling or servicing the battery modules. The end opposing theinsulative cap portion of the connector 30 provides an opening thatallows for electrical contact between the female terminal body containedwithin the connector and the positive and negative male terminals of thebattery modules when the connector is engaged within the battery modulesockets. The connector 30 further provides a set of interlocking arms31, 41, in which at least one of the interlocking arms 41 may comprise asequence tab 44.

Referring now to FIGS. 11 a, 11 b, 12 a, 12 b, 13, 14, 14 a and 14 b,the present invention also provides a means for decreasing the incidenceof electrical shocks to those handling high voltage battery modules 40.Typically, the module voltage is about 40-50 volts, but the voltage mayreach approximately 100 volts to approximately 600 volts if a pluralityof battery modules are connected together in series. During assemblingor servicing of battery modules which are connected in series, thesafety of the handlers becomes a concern when the positive maleterminals of two or more battery modules are connected in a manner thatallows for electrocution of the handlers by incidental contact to thepositive male terminals.

In one embodiment of the present invention, an insulating cap 50, asdepicted in FIGS. 11 a and 11 b, is positioned atop the upper portion ofeach positive male terminal 45 (also referred to as the positive malepost) in a plurality of battery modules, as depicted in FIG. 12 a.Referring to FIG. 11 b, the insulative cap 50 is snapped onto the upperportion of the positive male terminal 45 and has an exterior capdiameter D₂ slightly smaller than the male terminal diameter D₃, suchthat the female terminal can be easily engaged in electricalcommunication with the male terminal 45. In one embodiment of thepresent invention, the insulating cap 50 comprises an integrated snapring 56, wherein the integrated snap ring 56 engages into a groove 57 inthe upper portion of the positive male terminal 45 in order to securethe insulating cap 60 atop the positive male terminal 45.

Referring to FIGS. 12 a and 13, in one embodiment of the presentinvention, the spacing S₁ between the insulating shroud 55 of the socket35 and the insulating cap 50 ensure that those handling the seriesconnected battery modules can not contact the exposed portion 60 of thepositive male terminal 45 extending from below the insulating cap 50. Ina preferred embodiment, the spacing between the insulating shroud 55 andthe insulating cap 50 is limited to a 6 mm maximum in order to ensurethat the handlers can not contact the live portions (exposed portion 60)of the positive male terminal 45 and hence can not be electrocuted. Inthis embodiment, adjacent battery modules including the capped positiveterminals may be connected in series by connectors housing femaleterminals, in which the female terminals provide electricalcommunication between the positive and negative male terminals ofadjacent battery modules. Specifically, as depicted in FIG. 12 b, thefemale terminals contained within the conectors 30 a, 30 b, 30 c, 30 dand 30 e allow for a plurality of battery modules 40 a, 40 b, 40 c, 40d, 40 e, 40 f to be series connected using any assembly sequence, whileproviding a means to protect handlers from being electricuted.

Referring now to FIGS. 14, 14 a and 14 b, in another embodiment of thepresent invention, instead of capping all of the positive male terminalswith insulative caps, the incidence of electrocution during the assemblyor maintanence of battery modules in series may be substantially reducedby capping only the first positive male terminal with an insulating capand inserting the connectors in a sequence that ensures that each of thepositive male terminals of the series connected battery modules areprotected from incidental contact. In one embodiment of the presentinvention, a sequence tab extending from the insulating structure of theconnector ensures that as each connector is engaged into the sockets ofthe series connected battery modules the positive male terminal isprotected by the connectors insulating housing. The sequence tab ensuresthat each of the connectors is inserted in a sequential order thatprovides that the positive male terminal of each series connectedbattery module can not be reached or cause handlers of the seriesconnected battery modules to be electrocuted. The sequence in which theconnectors are engaged is now described in greater detail.

FIGS. 14, 14 a and 14 b depict a plurality of battery modules 40 a, 40b, 40 c, 40 d, 40 e, 40 f, in series connection through a plurality ofconnectors 30 a, 30 b, 30 c, 30 d, 30 e, in which each connector isengaged within a socket of adjacent battery modules providing electricalcommunication between the positive and negative battery modules. Eachconnector houses a female terminal (not shown) that provides electricalcommunication between the positive male terminal (also referred to aspositive male post) and the negative male terminal (also referred to asnegative male post) of adjacent battery terminals. Although theengagement of the connectors 30 a, 30 b, 30 c, 30 d, 30 e within theadjacent battery module's sockets 35 obstructs the view of theunderlying positive and negative male terminals, the positioning of themale terminals is illustrated in FIG. 14 by reference numbers 75 a, 75b, 75 c, 75 d, 75 e for the positive terminals, and reference numbers 76a, 76 b, 76 c, 76 d, 76 e for the negative terminals. In one instance,each connector 30 a, 30 b, 30 c, 30 d, 30 e provides an insulativestructure that houses a female terminal body, in which the femaleterminal body engages the negative male post of a first battery moduleand the positive male post of an adjacent battery module. The insulativestructure houses the female terminal body, shielding the female terminalbody from contact by handlers during assembly and servicing of thebattery modules.

Referring to FIGS. 14, 14 a, and 14 b, in the embodiments of the presentinvention in which only the first positive male terminal 75 a is cappedby an insulating cap 50, the insulating structure of the connectors 30a, 30 b, 30 c, 30 d, 30 e further includes a sequence tab 44 thatdictates the sequence in which the connectors 30 a, 30 b, 30 c, 30 d, 30e are engaged within the sockets 35 of adjacent battery modules inconnecting a plurality of battery modules, e.g. 40 a, 40 b, 40 c, 40 d,40 e, 40 f. In a preferred embodiment, the insulative structure of eachof the connectors 30 a further comprises at least two interlocking arms31, 41, wherein one of the interlocking arms 41 includes the sequencetab 44.

Still referring to FIGS. 14, 14 a, and 14 b, the sequence tab 44provides that as the first terminal 30 a connects the first two batterymodules 40 a, 40 b of the assembly sequence in a series that thepositive male terminal 75 b the second battery module 40 b of the seriesconnected battery modules 40 a, 40 b is protected from incidentalcontact by handlers. In this arrangement, although the positive maleterminal 75 b of the second battery module 75 b is covered by theinsulating structure of the housing, the negative male terminal 76 b maybe exposed. A second connector 30 b of the assembly sequence is thenengaged to connect the second and third battery modules 40 b, 40 c inseries connection, wherein the insulative structure of the secondconnector 30 b covers the negative male terminal 76 b of the secondbattery module 40 b, positive male terminal 75 c of the third batterymodule 40 c and leaves the negative male terminal 76 c of the thirdbattery module 40 c exposed. Another third connector 30 c of thesequence is then installed, and so on, until at the last battery module40 f, the last positive male terminal 75 f is covered by the insulativestructure of the last connector 30 e in the assembly sequence and thelast negative post 76 f is left exposed.

As shown in FIGS. 14, 14 a and 14 b, each interlocking arm 31, 41 ofeach connector comprises an overlying portion 32, 42 that extends atopan upper surface of the socket 35 in which the connector 30 a isengaged, and a vertical post 33, 43 extending downward from theoverlying portion 32, 42 of each interlocking arm 41, 42. Each verticalpost 33, 43 contacts the exterior of the socket's 35 sidewall. In oneembodiment of the present invention, an irreversible interlockingengagement is provided by a sequence tab 44 extending from one of theinterlocking arms 41, wherein the opposing interlocking arm 31 is notequipped with a sequence tab 44. More specifically, an irreversibleinterlocking engagement between a first connector 30 a and an adjacentconnector 30 b is provided by direct contact between the sequence tab 44that extends horizontally from the base portion of the vertical post 43of the interlocking arm 41 of a first connector 30 a and the verticalpost 43 of the interlocking arm of an adjacently positioned connector 30b.

In this embodiment of the interlocking arms, the top surface of thehorizontally extending tab 44 of a first terminal housing 30 a isdirectly contacted by the vertical post 33 of the adjacent terminalhousing 30 b to ensure that each connector 30 a, 30 b is engaged in anirreversible assembly sequence. It is noted that in this arrangement,the horizontally extending tab 44 is positioned on every other verticalpost 43, in which the vertical post 43 comprising the horizontallyextending sequence tab 44 is positioned along the positive male terminal(post)(+) (on left side of the socket's 35 sidewall) so that each of theconnectors 30 a, 30 b may be inserted into their respective sockets 35from right to left and may be removed from their respective sockets 35from left to right.

If the sequence in which the connectors are engaged into the sockets ofthe battery modules is alternated the battery modules cannot beconnected. For example, if the battery modules 40 b and 40 c are firstconnected by connector 30 b, the tab 44 of adjacent connector 30 a willbe stopped at the overlying portion 32 of the interlocking arm of thefirst connector 30, wherein the adjacent connector 30 a will beobstructed from being engaged. Reversely, during service, the connector30 c must be removed first followed by connector 30 b, and so on. Inthis fashion, no positive post which is in series connection is exposedduring the assembly or service process. Therefore, high voltage (on theorder of 100 volts to 600 volts) electrocution is avoided.

Although FIGS. 14, 14 a, and 14 b, depict the connectors illustrated inFIGS. 7 a-7 c and the female terminal bodies depicted in FIGS. 3 a-3 c,the above described assembly sequence and related structured are equallyapplicable to the female terminal bodies and connectors depicted inFIGS. 8-10.

Referring now to FIGS. 15 a, 15 b, and 15 c, in another embodiment ofthe present invention, a locking arrangement between the sockets and theconnector engaged therein is provided by a series of interlockingprotrusions 81 a, 81 b and windows 80 a, 80 b. More specifically, inembodiments of the present invention in which the terminal housing 30has locking windows 80 a and 80 b, the male connector socket has lockingprotrusions 81 a on one module and 81 b on an adjacent module. Whenterminal housing 30 is fully engaged within with battery module socket35, the protrusion 81 a and 81 b are dropped into locking window 80 aand 80 b, respectively. Therefore, the terminal housing is locked withinthe socket 35 and provides two adjacent modules.

The locking arrangement guarantees the orientation of interlocking armssuch that sequence connection must be followed and the connectionsequence is irreversible. Further, the locking arrangement guaranteesthat the disconnection sequence must be followed in reverse of theconnection sequence.

While the present invention has been particularly shown and describedwith respect to the preferred embodiments thereof, it will be understoodby those skilled in the art that the foregoing and other changes informs of details may be made without departing form the spirit and scopeof the present invention. It is therefore intended that the presentinvention not be limited to the exact forms and details described andillustrated, but fall within the scope of the appended claims.

1. An electrical connection comprising: a male terminal body comprisingan inserting portion; a female terminal body having at least one openend for receiving said inserting portion of said male terminal body,said female terminal body comprising a stamped groove positionedcorresponding to said inserted portion of said male terminal body whensaid female terminal body and said male terminal body are engaged; and acanted coil spring for providing an electrical interface between saidmale terminal body and said female terminal body, said canted coilspring positioned in said stamped groove.
 2. The electrical connectionof claim 1 wherein said canted coil spring is curvilinear in shape. 3.The electrical connection of claim 1 wherein said inserting portion ofsaid male terminal body comprises a rounded pin comprising at least onegroove, wherein said groove reversibly interlocks with said canted coilspring when said male terminal body and said female terminal body areengaged.
 4. The electrical connection terminal of claim 1 wherein saidfemale terminal body comprises a sheet of stamped metal comprising afolded portion, wherein said groove and said canted coil spring arecontained within said folded portion of said stamped metal.
 5. Theelectrical connection of claim 4 wherein a dimension defining a diameterof said canted coil spring is parallel to a dimension defining a lengthof said female terminal body or said dimension defining said diameter ofsaid canted coil spring is perpendicular to said dimension defining saidlength of said female terminal body.
 6. The electrical connection ofclaim 1 wherein at least one end of said female terminal body comprisesa substantially cylindrical or polyhedron shape.
 7. The electricalconnection of claim 1 wherein said female terminal body comprises two ormore open ends separated by an adjustable distance, wherein each of saidtwo or more open ends has a geometry for independently engaging saidmale connector body and said adjustable distance is provided by aU-shape joint.
 8. The electrical connection of claim 1 wherein saidfemale terminal body and said male terminal body are engaged in anunsealed engagement or sealed engagement.
 9. The electrical connector ofclaim 8 wherein said sealed engagement is provided by a female polymericstructure housing said female electrical connector and a male polymericstructure housing said male electrical connector, wherein engagingportions of said female polymeric structure and said male polymericstructure provide an interfacial seal when said male terminal body andsaid female terminal body are engaged.
 10. A method of forming a femaleterminal body comprising: providing a stamped metal panel comprising astamped groove about an opening for inserting a male terminal; insertinga canted coil spring into said stamped groove; and folding a portion ofsaid metal panel to contain said canted coil spring within said groove.11. An electrical power system comprising: a plurality of batterymodules in series connection between adjacent battery modules, whereineach battery module of said plurality of battery modules comprises apositive male terminal, a negative male terminal, and a socketcorresponding to each of said positive male terminal and said negativemale terminal; and a plurality of connectors, in which each connector ofsaid plurality of said connectors is in engagement with said socket ofsaid positive male terminal and said negative male terminal of saidadjacent battery modules, said each connector comprises an insulatingstructure housing a female terminal body, said female terminal bodyproviding said series connection between said positive male terminal andsaid negative male terminal of said adjacent battery modules, saidinsulating structure comprising a sequence tab configured to provide anirreversible engagement sequence for said each connector of saidplurality of connectors within said sockets of said adjacent batterymodules of said plurality of said battery modules, wherein saidirreversible engagement sequence positions said insulating structure ofsaid each connector on said positive male terminal of said plurality ofbattery modules in series connection between said adjacent batterymodules.
 12. The electrical power system of claim 11 wherein said femaleterminal body comprises at least two openings having a polyhedron shapeor substantially curvilinear shape.
 13. The electrical power system ofclaim 12 wherein said at least two openings of said female terminal bodycomprise a stamped groove containing a canted coil spring.
 14. Theelectrical power system of claim 11 wherein said connector comprises atleast one window and said socket comprises at least one lockingprotrusion, wherein when said connector is engaged in said socket saidat least one locking protrusion interlocks with said at least onewindow.
 15. The electrical power system of claim 11 wherein saidinsulating structure of said connector comprises at least twointerlocking arms that each engage a sidewall of said socket, whereineach of said at least two interlocking arms comprises overlying portionsatop an upper surface of said socket and vertical posts extendingdownward from said overlying portion of said interlocking arms alongexterior portions of sidewalls of said each of said socket, wherein oneof said interlocking arms comprises said sequence tab horizontallyextending from a base portion of said one of said vertical posts,wherein said sequence tab is directly contacted by an adjacent verticalposts of an adjacent connector when said adjacent connector is engagedinto an adjacent socket of said adjacent battery module.
 16. Theelectrical power system of claim 11 further comprising a first positivemale terminal positioned on a first battery module of said plurality ofbattery modules, said first positive male terminal comprising aninsulating cap positioned atop an upper portion of said first positivemale terminal leaving a lower portion of said first positive maleterminal exposed and an insulating shroud around said lower portion ofsaid first positive male terminal, wherein the dimension separating saidinsulating cap from said insulating shroud obstructs incidental contactto said lower portion of said first positive male terminal.
 17. A methodof assembling a series of battery modules comprising: providing aplurality of battery modules, in which each battery module of saidplurality of battery modules comprises a positive male terminal and anegative male terminal; capping a first positive male terminal on afirst battery module of said plurality of battery modules with aninsulative cap leaving a first negative male terminal on said firstbattery module exposed; engaging a first connector in series connectionwith said first negative male terminal of said first battery module anda second positive male terminal of a second battery module, leaving asecond negative terminal of said second battery module exposed, whereina first insulating housing of said first connector protects said secondpositive male terminal and comprises a first sequence proximate to saidsecond positive male terminal and an post proximate to said firstnegative male terminal; and engaging a second connector in seriesconnection with said second negative male terminal of said secondbattery module and a third positive male terminal of a third batterymodule, leaving a third negative male terminal of said third batterymodule exposed, said second connector comprising a second insulatinghousing substantially similar in geometry to said first insulatinghousing that protects said third positive male terminal, whereinengagement of said first sequence tab of said first connector and asecond post of said second connector provides an irreversible assemblysequence.
 18. An electrical power system comprising: a plurality ofbattery modules in series connection between adjacent battery modules,wherein each battery module of said plurality of battery modulescomprises a positive male terminal, a negative male terminal, and asocket corresponding to each of said positive male terminal and saidnegative male terminal, wherein said positive male terminal comprises aninsulating cap positioned atop an upper portion of said positive maleterminal leaving a lower portion of said positive male terminal exposedand an insulating shroud of said socket around said lower portion ofsaid positive male terminal, wherein a dimension separating saidinsulating cap from said insulating shroud obstructs incidental humancontact to said lower portion of said positive male terminal; and aplurality of connectors, in which each connector of said plurality ofconnectors is in engagement with said socket of said positive maleterminal and said negative male terminal of said adjacent batterymodules, wherein said each connector comprises an insulating structurehousing a female terminal body providing said series connection betweensaid positive male terminal and said negative male terminal of saidadjacent battery modules.
 19. The electrical power system of claim 18wherein said plurality of connectors comprises windows and said socketcomprises locking protrusions, wherein when said each connector of saidplurality of connectors in engaged in said socket said lockingprotrusion interlock with said windows.
 20. The electrical power systemof claim 18 wherein said openings of said female terminal body comprisea stamped groove containing a canted coil spring.